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Procedia CIRP 63 (2017) 610 – 614
Abstract
This experimental research on cryogenic turning process involves the modelling and optimization of the process parameters affecting the
machining performance and value oriented sustainable manufacturing. In the present work, the machining parameters namely the cutting speed,
feed rate, depth of cut and rake angle are optimized for minimum surface roughness on AISI 4340 steel. The experimentation was planned
XVLQJ7DJXFKL¶V/WKHRU\ An orthogonal array (L9), the signal-to-noise (S/N) ratio, and the Qualitek-4 were employed to the study the surface
roughness in the turning of AISI 4340 steel under cryogenic condition. It was observed that cutting speed and depth of cut was the most
influential factors on the surface roughness. To validate the study, confirmation experiment has been carried out at optimum set of parameters
and predicted results have been found to be in good agreement with experimental findings. The results have revealed that cryogenic machining
has yielded better surface finish.
©©2017
2017TheTheAuthors. Published
Authors. by Elsevier
Published B.V.B.V.
by Elsevier This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility ofthe scientific committee of The 50th CIRP Conference on Manufacturing Systems.
Peer-review under responsibility of the scientific committee of The 50th CIRP Conference on Manufacturing Systems
Keywords: Cryogenic Turning; Surface roughness; Taguchi method
2212-8271 © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 50th CIRP Conference on Manufacturing Systems
doi:10.1016/j.procir.2017.03.166
Sanchit Kumar Khare and Sanjay Agarwal / Procedia CIRP 63 (2017) 610 – 614 611
2. Literature Review vibrations along three axes were chosen for in-process
surface roughness prediction system. By using multiple
Paul et al [4] investigated the effects of cryogenic cooling regression and Analysis of Variance (ANOVA) a strong
in machining of AISI 1060 steel with carbide inserts and linear relationship among the parameters (feed rate and
compared the effectiveness of cryogenic cooling with that vibration measured in three axes) and the response (surface
of dry machining and conventional cutting fluids. roughness) was found. The authors demonstrated that
Experimental results indicate that cryogenic cooling spindle speed and depth of cut might not necessarily have
provided reduced tool wear and improved surface finish, to be fixed for an effective surface roughness prediction
compared to dry and wet operations. model.
Zhou et al. (1995) [5] investigated on tool life criteria in Ramakrishnan and Karunamoorthy [12] developed an
cryogenic turning. A new tool-life criterion depending on a Artificial Neural Network (ANN) by using Inconel 718 as
pattern-recognition technique was proposed and neural work material to predict the performance characteristics
network and wavelet techniques were used to realize the namely MRR and surface
new criterion. The experimental results showed that this URXJKQHVV EDVHG RQ 7DJXFKL¶V / RUWKRJRQDO DUUD\ 7KH
criterion was applicable to tool condition monitoring in a response by optimized concurrently using multi-response
wide range of cutting conditions. signal-to-noise (MRSN) ratio in DGGLWLRQ WR 7DJXFKL¶V
Lin et al. (2001) [6] adopted an abdicative network to parametric design approach. ANOVA was employed to
construct a prediction model for surface roughness and identify the level of importance of the machining
MRR. Once the process parameters: cutting speed, feed parameters on the multi-performance characteristics.
rate and depth of cut were given; the surface roughness From the literature, it is observed that researchers have
and MRR could be predicted by this network. Regression already worked in the area of cryogenic turning
analysis was also adopted as second prediction model for technology.
surface roughness and MRR.
Feng and Wang (2002) [7] investigated for the prediction In recent years, along with other types of steels, AISI
of surface roughness in finish cryogenic turning operation 4340 steel has also emerged as an important material for
by developing an empirical model through considering industrial applications. Despite extensive research on
working parameters: work piece hardness (material), feed, cryogenic turning process, determining the desirable
cutting tool point angle, depth of cut, spindle speed, and operating conditions during cryogenic turning of AISI
cutting time. Data mining techniques, nonlinear regression 4340 steel, in industrial setting, still relies on the skill of
analysis with logarithmic data transformation were the operators and trial-and-error methods. So the aim of
employed for developing the empirical model to predict the present work is to obtain the optimum machining
the surface roughness.
conditions for cryogenic turning of AISI 4340 steel, for
Suresh et al. (2002) [8]focused on machining mild steel by
minimizing the surface roughness based on Taguchi
TiN-coated tungsten carbide(CNMG) cutting tools for
technique. Experiments were carried out to study the
developing a surface roughness prediction model by using
Response Surface Methodology (RSM). Genetic effect of various parameters viz. speed, feed, depth of
Algorithms (GA) used to optimize the objective function cut and rake angle on the surface finish. The levels of
and compared with RSM results. It was observed that GA significance on the surface roughness were statistically
program provided minimum and maximum values of evaluated by using Qualitek-4.
surface roughness and their respective optimal machining
conditions. 3. Experiment
Lee and Chen (2003) [9] highlighted on artificial neural The experimental studies were performed on a High-
networks (OSRR-ANN) using a sensing technique to power rigid lathe machine tool. The composition of AISI
monitor the effect of vibration produced by the motions of 4340 steel work-piece material used for experimentation
the cutting tool and work piece during the cutting process in this work is a given in table 1. HSS T-42, S-400 (CT)
developed an on-line surface recognition system. The Ǝ[ Ǝ VLQJOH SRLQW WXUQLQJ WRRO was used in the
authors employed tri-axial accelerometer for determining experiments. The parameters, selected for different
the direction of vibration that significantly affected surface settings of speed, feed, depth of cut and rake angle were
roughness then analyzed by using a statistical method and used in the experiments (Table 2). The photographic
compared prediction accuracy of both the ANN and SMR. view of the machining zone has been shown in fig.1 (a).
Choudhury and Bartarya (2003) [10] focused on design of The other details of the experimentation have been
experiments and the neural network for prediction of tool shown in Table 3. The surface roughness was measured
wear. The input parameters were cutting speed, feed and by with Stylus-type profilometer, Talysurf (Taylor
depth of cut; flank wear, surface finish and cutting zone Hobson, Surtronic 3+) on the work-piece after machining.
temperature were selected as outputs. Empirical relation Stylus-type profilometer has been shown in fig.1 (b).
between different responses and input variables and also
through neural network (NN) program helped in Table-1 Chemical composition of AISI D3 steel (wt %)
predictions for all the three response variables and
compared which method was best for the prediction.
Kirby et al. (2004) [11] developed the prediction model for AISI C-0.382, S-0.022, P-0.026, Si-0.228, Mn-0.609,
4340
surface roughness in turning operation. The regression Cr-0.995, Ni-1.514, Mo- 0.226, Fe-95.998
model was developed by a single cutting parameter and
612 Sanchit Kumar Khare and Sanjay Agarwal / Procedia CIRP 63 (2017) 610 – 614
Table-2 Machining settings used in the experiments purpose of designing and improving the product quality
[13,14]. In the Taguchi method, process parameters which
Process variables influence the products are separated into two main groups:
Values Cutting Speed Feed Depth of Rake control factors and noise factors. The control factors are
in (N) Rate(f) cut(d) (mm) angle used to select the best conditions for stability in design or
coded (rpm) (mm/rev) (Į manufacturing process, whereas the noise factors denote
form
all factors that cause variation.
L1 50 0.045 0.2 4 According to Taguchi based methodology, the
L2 150 0.090 0.4 8 characteristic that the smaller value indicates the better
L3 250 0.135 0.6 12 machining performance, such as Surface roughness is
addressed as the-smaller-the-better type of problem. The
615DWLRLHȘFDQEHFDOFXODWHGDVVKRZQEHORZ
Table-3 Fixed parameters Smaller-the-better
Ș -10 log ( ) (1)
Work piece AISI 4340 steel rod
To evaluate the effects of cutting parameters of cryogenic 7 250 0.045 0.6 8 5.66 -15.0563
turning process in terms of cutting performance 8 250 0.090 0.2 12 2.40 -7.6042
characteristics such as Surface Roughness a Taguchi 250 0.135 0.4 4 3.66 -11.2696
9
method used here to model the cryogenic turning process.
In this study, Taguchi method, a powerful tool for
parameter design of performance characteristics, for the
Sanchit Kumar Khare and Sanjay Agarwal / Procedia CIRP 63 (2017) 610 – 614 613
Table5. Response Table for S/N ratio the SR are speed and depth of cut. The percent
contributions of the machining parameters on the SR are
shown in Table 7. Speed is found to be the major factor
affecting the SR (50.847%). The percent contribution of
depth of cut and rake angle on the SR are 30.915%,
6.415% respectively.
6.415%
50.84%
30.915%
At least 95% confidence SR has reasonable accuracy for resulting model because an
error of 5.32% for S/N ratio of SR is measured.
According to F-test analysis, the significant parameters on
614 Sanchit Kumar Khare and Sanjay Agarwal / Procedia CIRP 63 (2017) 610 – 614
Acknowledgement
References